ES2207290T3 - METHOD IN TONINUO TO MANUFACTURE A THREE-DIMENSIONAL CANDLE. - Google Patents

Abstract

A three dimensional sail of one piece construction is made on a rotating roll having a deformable outer surface. The roll is divided into a large number of segments, extending across the width of the roll, with the convex profile of each segment being adjustable. A sail is made on the roll on a continuous basis by applying a first layer of film, deforming the film on the roll, applying adhesive and reinforcing the yarns, and applying a second layer of film to form a 3-D laminate.

Description

Continuous method to make a candle three-dimensional

Background of the invention

This invention relates to a method for continuous manufacture of sails for sailboats and, more particularly, to the manufacture of stratified candles and molded

Modern conventional candles for sailing vessels are not flat, but have a way of three-dimensional sheet Until now, most of the candles they have been manufactured from panels or flat fragments of woven fabric, of laminated cloth and film, or of film laminates reinforced with threads or canvas. In first place, flat panels are cut to get a shape default, and the panels are then joined together to what along its adjacent edges. In a procedure called stitched thick or wide pitch, it is possible to bend one or both edges adjacent panels, so that subsequent sewing It gives rise to an approximately three-dimensional shape.

The construction of a candle in a static mold It is well known, and is described in Wagner European Patent No. EP 056657, in US Gardiner Patent No. 2,565,219, and in Baudet U.S. Patent No. 5,097,784.

Baudet's patent describes a candle three-dimensional one-piece that lacks seams and panels. The candle has been built in a convex mold that has a three-dimensional shape, and the mold shape is susceptible to adjust to the desired shape for the candle. A first layer of film is deposited on the mold, reinforcing threads are applied by means of a bridge-crane located above, at which follows the application of a final film layer. The stratified is then heated under pressure in order to bind adhesives and have the laminate permanently adopt The shape of the mold. Candles of this type are marketed, in the currently, for the North Sails under the trademark "3DL", and have achieved remarkable commercial success.

While the candle described in patent no. 5,097,784 has superior qualities compared to candles Conventionally manufactured from sewn individual panels, the procedure to make this candle is very laborious and It consumes a lot of time. The mold must be what large enough to accommodate a wide variety of candle sizes, and only a single candle can be made in the mold every time. Also, the mold itself is a structure complicated and expensive, and in the procedure can occur variables that require careful control.

Summary of the invention

In accordance with the present invention, it is manufactured a three-dimensional candle with a one-piece construction on a roller that rotates slowly and has a surface deformable exterior The roller is divided into a plurality of segments, which extend across the entire width of the roller, such that the profile of each segment can be adjusted in independently and individually to adopt a curved shape and convex that corresponds, in proportion, to the profile, of the part before the subsequent, of the candle, in successive segments of the candle. The profile of the segments can be adjusted by rows of adjustable pistons that extend radially towards out from the central portion of the roller. The rows of pistons they are attached to rectilinear and flexible members that form a support surface on the roller.

A continuous band (s) of film polymer unwinds (n) from a roll or rolls, and it is applied on a non-deformed cylindrical portion of the roller, in order to provide a continuous film layer bottom or base. As the roller rotates, the successive sectors or sections of the film are heated, while imparts a certain curvature to each sector, in such a way that imparts a normally different degree of profile curvature to successive sectors, which causes permanent deformation of the movie. The profile of each roller sector is kept tailored which rotates each roller, and the support film passes through areas of adhesive application device and of thread application device. In this last zone, about thread application devices capable of moving and located above the roller, reinforcement threads are applied coated with adhesive to the film in a programmed way. These application devices are capable of tending threads to through the roller and along the entire length of the film, and forming certain angles with it.

A second forming roller has been arranged, intended to heat and deform a second layer of film, of so that it matches the lower film layer or of base. The second film layer, or top film layer, a once deformed until adopting a three-dimensional shape and arranged in coincidence with the shape of the first layer, it is applied to the base film and forms an encapsulation on the network of threads of reinforcement. Alternatively, the second film layer is deposited directly from supply rolls on the roller primary or main for its conformed. Following this stage, the laminate thus assembled is subjected to heating and to compression while it is supported on the roller with profile. The compression stage may comprise the stages of puncturing or pierce the base film layer before applying the second layer of film, followed by the application of the second film and the application of vacuum or suction through the perforations, in order to exert a suction effect on the two films until both are linked together. Preferably, the film is perforated before application of the drum. The laminate is heated by means of an air flow hot, which causes the adhesive to flow and adhere tightly with each other layers.

The resulting three-dimensional laminate is cools and is removed from the forming cylinder, and the profile of the successive sectors or sections of roller is returned to the form no deformed or cylindrical, in order to receive a new base film flat.

The length of the candle that is manufactured is not limited by the circumference of the roller, since the profile of The sectors can be adjusted to a large degree. In this way, the procedure allows the production of candles in a continuous way and uninterrupted, which is only limited by supply continuous film and raw thread. In comparison with the methods that use static molds, savings are achieved substantial time and elaboration work. The design, the weight per unit area, the size and shape of the candle is incorporate a computer program that automates the adjustment of the profile of the roller sectors and the arrangement and density of the reinforcing threads. So, except for the possible trimming and finishing operations, the procedure is continuous and automatic.

Description of preferred embodiments

The method of the present invention will be described. first and generally in relation to Figures 1 to 4. The method will be described with reference to a candle completed 50 shown in Figure 5. The candle completed it will typically have a triangular shape and will comprise a head 51, or top vertex, a clenched fist 52, or front vertex bottom, and a fist of amura 53. The three edges of a candle are define as the graph 54, or leading edge, the edge of amura 55 or trailing edge, and foot 56, or bottom edge. The finished candle it is a laminate comprising two outer film layers 57 and an internal net or mesh of reinforcement threads. The threads 58 are they extend, generally, from the top to the part bottom or bottom of the candle, and include threads that converge towards the vertices Threads 59 generally extend through the candle and between the two bottom or bottom vertices.

As shown in the Figures 1-4, the candle is manufactured on a roller 10 that turn counterclockwise, as shown in Figures 1 and 2. A perforated film base layer 12 is apply on the roller across its width. The film 12 may have been previously coated with an adhesive, the covering tape may have been removed, and the edges adjacent film may have been arranged overlapping between yes. The film may consist of bands that unwind from rolls 14 and 16 located in staggered positions, and are joined between yes along the opposite or overlapping edges by means of an adhesive tape that is supplied from a roll 18, being the joined bands guided by the guide roller 20 under a uniform tension During processing, the film layer of base 12 is held on the surface of the roller by the application of a partial vacuum through the cylindrical wall of roller, as described in the following.

The roller has a flexible surface and deformable on which segments 13 of adjacent surface (Figure 2) located transversely to the roller, that is, parallel to the axis of rotation, until reaching successive profiles curved convexly. Film layer base 12 is heated, first, by means of a heater hot air or radiation 22 located adjacent to the roller, a In order to soften the movie. In the area designated by an arrow with reference 24, the roller segment that supports the film heated deforms in order to cause the film to deformed along contiguous and narrow segments, transversely to the roller.

Figures 3 and 4 schematically show a roller 10 having a flexible outer surface 26, so that the surface profile is adjusted by means of pistons 28. The Figure 3 shows the pistons in a neutral position in which the outer surface segment is cylindrical. Figure 4 shows the adjustment of the pistons such that the surface 26 bends until reaching the shape of a surface or support wing. As shown in Figure 4, and in relation to Figure 5, the graph 54 or leading edge portion of the base film of the Candle will be placed on the left side of the drawing, and the edge of amura 55 or leading edge of the candle will be placed on, or in the proximities of, the right edge. Since the movie is being deformed along a curved profile in the direction transverse and is wrapped around the cylinder according to the direction longitudinal or machine direction, the film is deforming in a way that varies successively and in three dimensions. In other words, both the curvature of the roller around its circumference as the curved profile of the sectors contribute, both, to the permanent deformation of the film, so that The Gaussian curvature of the original design of the candle is maintained at all points of its surface.

When the roller reaches the end of the arrow 24, the pistons 28 are locked in order to maintain the profile of the sailing sector until all the subsequent processing stages. Since the curvature or tracing a candle varies from the head or top of the same to the foot or bottom, the transverse curvature of The successive curvature profiles changes.

The shape and dimensions of the candles are determined from standard models, and all the necessary information to This can be stored in the form of data on a computer. Is information can be transformed into signals that cause adjustment individual of each of the pistons 28 of each successive row. Using a bow sail or jib as an example, the path or magnitude of the curvature will be greater in the vicinity of the graph 54, and the density or number of pistons 28 will be higher in this area, as shown in Figures 4 and 4a.

Figure 4a illustrates the principle consisting of use only a portion of the width of the roller to make candles that have smaller widths. In such case, the roller it will be deformed on its left side, leaving its right side without deform.

After heating and deformation, the film is coated with adhesive, such as by a spray head 30, which applies adhesive in liquid form and moves back and forth transversely to the film surface, while moving with the surface to obtain a parallel passage to the axis of the cylinder. In the preferred embodiment, the film is previously coated with a adhesive. The adhesive is preferably of the thermoplastic type or heat fuse

The film coated with scrollable adhesive then passes under a plurality of stations 32 and 34 to the application of reinforcement thread in the film. The seasons 32 are separated from each other in order to ensure adequate coverage of the threads about the movie. The stations comprise beams of transverse and fixed support 33, which are provided with automatic thread dispensers 35 that are mounted so mobile over them, and in which the thread is guided and applied on the film by means of rollers 37. The dispensers 32 move back and forth through of the moving film, and apply threads 58 in such a way that extend from the top 51 to the bottom 56 of the candle (Figure 5), or forming acute angles with it. Like all modern candles are triangular, stations 32 they will apply threads that will spread diverging continuously from the upper vertex or head 51 when penetrating the body of the candle, and converging when approaching the two lower vertices of the clew 52 and the fist of amura 53. Preferably, the Thread is previously coated with an adhesive.

Station 34 serves to apply wires 59 to across the width of the film, such as between the fist of notch 52 and the fist of amura 53, and so that the others cross threads 58 between the edges of the candle. All threads 58 and 59 are preferably applied in a continuous and uninterrupted way, of vertex to vertex, from vertex to edge, or from edge to edge. As shown in Figure 2, station 34 and device 30 Adhesive application can be mounted on radial arms motorized 31 and 33, in order to allow the movement of application devices in the direction of movement of the movie.

Once a sufficient number has been applied of threads according to the desired configuration to complete a candle individually, the threads can be supplied continuously from the application devices to an adjacent area of the movie, in order to define the next candle. As an alternative, threads can be cut and repositioned by Application devices for the beginning of a new candle.

The threads may be composed of any of the known types of which are used in modern manufacturing of candles. These typically include continuous filament threads twisted, or twisted, and not twisted, composed of polymers such as polyester, aramid, oriented fiber polyethylene and similar, as well as single strands of single filament. The denier of the threads can be adjusted to fit the weight or type particular candle that is being manufactured, and the number and density  of the threads can be programmed in order to provide the weight wanted. In addition, as described in US Pat. Baudet No. 5,097,784, the threads are preferably applied according to a configuration calculated in such a way that they adapt optimally to the main tension lines of the candle when the candle is being used, so that the threads will emerge separating as of radii from the vertices. Other threads may be arranged intersecting the main threads, in order to provide support for various navigation angles and resist tearing.

The composition of the film can be any of those available and used in modern stratified for sailing. Typically, films of stretch-resistant polyester, although others are known types that can be used.

After the application of the threads, it is applied a second layer of film 40 on the first layer, which now It incorporates the threads and the adhesive on its exposed surface. The second layer of film 40 is not perforated and can be supplied in the form of bands obtained from rolls 42 that join together by means of an adhesive tape 44, or, if they have been coated, overlapping its edges. The movie 40 can conform on a second independent roller, smaller and deformable 46, which is provided with a heater 48. The roller 46 it also has a profiled surface that fits so continues, such that the film 40 deforms to match with perforated base film 12 located on roller 10. In the preferred embodiment, the film is not preformed, but it can be fed, with a flat shape, directly to the primary or main roller moving around a roller crazy similar to roller 20 located upstream of heater 60. In this way, the second film layer will deform only by the action of the previous roller 10. The film 40 is supplied on the roller 10 in order to form a layer structure or stratified, and said structure is passed under a heater 60, which heats it. In the indicated roller position by arrow 62, a high magnitude vacuum is applied or intensity. The vacuum is produced by aspiration through the perforated base film 12, which makes the two layers of film be pressed against each other by aspiration at the same time that are heated to harden the adhesive, thereby forming a permanent stratified.

The laminate already completed 63 is removed to continuation of the forming roller and can be rolled in a pickup roll 65. The candle can be finished by cutting it from the sheet and carrying out any finishing operations. The resulting candle, as shown in Figure 5, is a structure unitary, lacking seams and panels or fragments.

The apparatus of the present invention can used to make independent and ready candles successively on a continuous basis, as well as candles that have portions that overlap within the base film layer. The latter is illustrated in Figure 6, in which three are used layers or bands of film 64a, 64b and 64c arranged edge with edge. Dimension 66 is equal to one meter, and dimension 68 is equal to an envelope length of the film on the roller. It can be seen that certain portions of successive candles, such such as those designated by 70 and 72, can be superimposed, in such a way portions of two candles are produced at the same time. The size of the sail is limited by the maximum width of the roller and the film, which is measured, in most cases, at foot length

Figure 7 shows the roller in section cross section, and Figure 8 shows a cross section of a piston assembly and roller cover. The roller 10 is mounted on a frame or support frame 74 that has supports inner and outer 76 and 78 for pistons 80. The end outer piston 80 is attached to a flexible slat 82 that is extends across the width of the roller. The piston includes a blocking device 84 (Figure 8) intended to block the piston in an advanced position, and the piston rods or rods are advance sequentially by means of a device drive 86. The piston rods are hollow and attached to vacuum lines 88 leading to a surface flexible 90 covering the slats 82. If desired, it is possible use independent vacuum lines to the surface. The flexible surface may comprise an elastomer layer endowed with texture and that has openings for the vacuum, being covering said layer with a permeable fabric intended to distribute vacuum evenly over the surface.

As shown, a drive device 92 retractable, pneumatically actuated or threaded, engages the piston rod 80 and rotate with it as the piston is shifted radially out to the desired position. The locking device 84 locks the piston in position extended, and a second device of drive 96 in order to unlock the piston at the end of the drum rotation cycle and return the piston to its starting position The pistons are returned to their neutral position in the arch (Figure 1), once the laminate has been removed from the roller.

Figures 9-11 illustrate a alternative and preferred arrangement to provide a frame deformable for the outer surface of the forming cylinder and support 10. A first plurality of flexible bars has been formed 110 inside parallel circles with telescopic ends, in order of defining the support portion of the roller circumference. A second plurality of flexible bars 112 has been arranged forming right angles with the first plurality 110 and located by on top of it, and those extend parallel to the axis of roller 10. Bars 110 and 112 are preferably tied between yes, for example, by a flexible strip 114 which has a plurality of separate openings 116 made therein and arranged along a line. The openings 116 pass to through bars 112 in separate positions and are arranged linked upward around the circumferential bars 110 a  in order to embrace the whole holding it together in a way flexible. The set is covered with one or more elastic sheets, such and as explained above, in order to provide a shaping surface. The circumferential bars are attached to pistons 118 by means of drilled rods 120, in order to selectively expand and reduce the assembly radially a radial direction

In practice, as a practical example, the bar or main stem will have a diameter of 3,048 m (120 inches), and will have a width greater than 4,572 m (180 inches), in order to adapt to the width of three rolls of film with a standard width of 1,524 m (60 inches). Will be used approximately 1,000 pistons, so that each row contains between 20 and 30 pistons, with an extension of up to 0.152 m (6 inches). It is estimated that manufacturing will take place at a speed  surface of approximately 0.051 m (2 inches) per second, of in such a way that 3,300 meters of film divided between 6 rolls, 215,000 meters of thread warp, 150,000 meters of fill or weft thread, and approximately 47,627 kg (105 pounds) of adhesive.

Preferably, each of the devices of thread application is capable of laying more than one individual thread of once, although it is important that the threads are not tied or linked each other transversely in a form such as a tape, in order to allow each individual thread to follow it in its trajectory as they are applied, in order to guarantee a smooth application

Claims (13)

1. A method of manufacturing a laminate flexible and three-dimensional, said method comprising the stages of apply a layer of base film on a rotating roller that has adjacent sectors or sections, warp those sectors adjacent transversely to the roller in order to deform successive profile segments of said base film up to give them a three-dimensional shape, apply an adhesive and reinforcement elements to said base film, and apply a layer of top film on base film layer while found on said roller, in order to form a stratified 2. The method according to claim 1, in which said film is heated while it is being distorted. 3. The method according to claim 1, in which heat and pressure are applied to the laminate in order of hardening or curing the adhesive. 4. The method according to claim 3, in which the base film is air permeable and the layer of upper film is waterproof, and in which pressure is applied to the create a vacuum aspiration effect through the layer of permeable base film. 5. The method according to claim 1, in which the stage of applying a top film layer comprises the stage of first deforming the film layer top in order to match the profile segments of the base film layer. 6. The method according to claim 5, wherein said upper film layer deforms on a second rotating roller. 7. The method according to claim 1, in which said reinforcing elements comprise threads continuous 8. The method according to claim 1, in which said three-dimensional and flexible stratified is a candle. 9. The method according to claim 1, in which said candle has a triangular shape and presents vertices 10. The method according to claim 8, wherein said reinforcing elements comprise continuous threads that extend between the edges of the candle. 11. The method according to claim 1, in which said successive deformed profile segments belonging to said base film are kept on said roller until said laminate is removed from said roller. 12. The method according to claim 1, in which a vacuum is maintained in said base film layer in order to temporarily adhere said layer to said roller. 13. An apparatus intended to manufacture a three-dimensional stratified one-piece, comprising said apparatus a rotating roller (10) having an outer surface (26), a plurality of flexible segments (13) that define the outer surface profile (26), means (28) intended for adjust the individual segments (13), and means (14, 16, 18, 20) intended to apply a film (12) on the outer surface (26) of the roller (10).